Sol - Brinesolbrine.uest.gr/uploads/files/deliverable_3.1.pdf · pilot brine treatment system 5 | P a g e 1 Introduction 1.1 Background & Concept The pilot brine treatment system

Development of an advanced, innovative,

energy autonomous system for the treatment

of brine from seawater desalination plants

SOL-BRINE

Deliverable 3.1 Technical report on the construction and installation of the innovative solar-driven pilot brine treatment system

Action 3 Engineering, construction and installation of the innovative, pilot-scale, energy-autonomous, brine treatment system at

the desalination plant of Tinos

Prepared by

Tinos

NTUA

Culligan S.A

Athens, October 2012

LIFE+ Environment project: LIFE09 ENV/GR/000299

Sol - Brine

Deliverable 3.1: Technical report on the construction and installation of the pilot brine

treatment system

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Acknowledgements

This report was produced under co-finance of the European financial instrument for the

Environment (LIFE+) as the first Deliverable (D3.1) of the third Action (Action 3) of Project

“SOL-BRINE” (LIFE 09 ENV/GR/000299) entitled “Engineering, construction and installation

of the innovative, pilot-scale, energy-autonomous, brine treatment system at the

desalination plant of Tinos”.

SOL-BRINE team would like to acknowledge the European financial instrument for the

Environment (LIFE+) for the financial support1.

Disclaimer

The information included herein is legal and true to the best possible knowledge of the

authors, as it is the product of the utilization and synthesis of the referenced sources, for

which the authors cannot be held accountable.

1 The authors can be contacted for enquiries, corrections or other remarks at

[email protected]

mailto:[email protected]


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Contents

EXECUTIVE SUMMARY ..................................................................................................... 3

ΠΕΡΙΛΗΨΗ ΣΤΑ ΕΛΛΗΝΙΚΑ ............................................................................................ 5

1 INTRODUCTION ............................................................................................................. 5

1.1 Background & Concept ...................................................................................................................... 5

1.2 Process description ............................................................................................................................. 6

2 TENDERING ...................................................................................................................10

2.1 Type of tendering and process .....................................................................................................10

2.2 Received offers and final selection .............................................................................................10

2.3 Detailed budget ...................................................................................................................................11

2.4 Terms of the contract .......................................................................................................................12

3 CONSTRUCTION ...........................................................................................................13

4 INSTALLATION .............................................................................................................21

4.1 Basic description of the site ...........................................................................................................21

4.2 Civil work ...............................................................................................................................................23

4.3 Installation of the equipment .......................................................................................................25

4.4 Control ....................................................................................................................................................32

5 ANNEXES ........................................................................................................................35


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List of figures

Figure 1-1: SOL-BRINE concept .................................................................................................. 5

Figure 1-2: Single line diagram of the pilot brine treatment system ........................................ 8

Figure 1-3: Mass balance of the pilot brine treatment system. The quantities of distilled

water produced are marked in pink, while the salt in blue color. ............................................ 9

Figure 3-1: Raw materials (Super Duplex tubes and plates) ................................................... 14

Figure 3-2: Photos from the construction of the evaporator unit .......................................... 15

Figure 4-1: Views of the site of the desalination plant at Agios Fokas, Tinos Island............... 21

Figure 4-2: Site of the pilot brine treatment plant .................................................................. 22

Figure 4-3: Site preparation works of the area where the pilot system was installed ........... 23

Figure 4-4: Civil works for laying down the foundations of the system .................................. 24

Figure 4-5: Foundations of the brine treatment system ......................................................... 24

Figure 4-6: Layout of pilot brine treatment system ................................................................ 26

Figure 4-7: Solar system .......................................................................................................... 27

Figure 4-8: Installation of the dryer ......................................................................................... 28

Figure 4-9: Transportation of the evaporator unit from the manufacturer’s workshop

facilities .................................................................................................................................... 29

Figure 4-10: Details from the fully installed evaporator unit .................................................. 30

Figure 4-11: Crystallizer unit .................................................................................................... 31

Figure 5-1: Engineering drawings of the evaporator vessel (Effects 1&2) .............................. 35

Figure 5-2: Process and Instrumentation Diagram (P&ID) ...................................................... 36

Figure 5-3: Products discharge vessels (two identical vessels: one for the fresh water

produced and one for the treated brine (crystallizer)) ........................................................... 37

file:///C:/Back%20up/My%20documents/Υλοποίηση%20προγραμμάτων/SOLBRINE/Deliverables/Action%203/Deliverable%203.1_Final%20Version_8_1_2013.docx%23_Toc348959028file:///C:/Back%20up/My%20documents/Υλοποίηση%20προγραμμάτων/SOLBRINE/Deliverables/Action%203/Deliverable%203.1_Final%20Version_8_1_2013.docx%23_Toc348959028


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Figure 5-4: Tube in Tube Heat Exchanger ............................................................................... 38

Figure 5-5: 3-D Views of the evaporator unit .......................................................................... 39

Figure 5-6: Drawing of the dryer ............................................................................................. 40

List of tables

Table 2-1: Cost breakdown of the pilot brine treatment system ............................................ 11

Table 3-1: List of suppliers/ manufacturers contacted ........................................................... 16

Table 4-1: Instruments for the control and monitoring of the prototype brine treatment

system...................................................................................................................................... 33

Abbreviations and Acronyms

ITT Invitation To Tender

ZLD Zero Liquid Discharge


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Executive summary

This report provides information on the construction and installation of a prototype brine

treatment system that was developed in the context of the EU funded project with the

acronym SOL-BRINE (LIFE09 ENV/GR/000299). The developed system aims at eliminating

the brine generated from desalination plants and it will be powered through solar energy

(energy autonomous operation). The brine is produced by the reverse osmosis unit

(1,000m3/day capacity) that currently operates at the region of Agios Fokas on Tinos Island,

Greece. The objective of the prototype unit is not to solve the environmental problems

associated with the total brine produced by the operation of Agios Fokas desalination unit

but to test and demonstrate the innovative brine treatment approach that will lead to zero

liquid discharge while achieving high water recovery and production of dry salt with market

prospect.

In the context of the LIFE+ SOL-BRINE project and in specific within the framework of Action

3, the engineering, construction and installation of the pilot-scale, energy-autonomous,

brine treatment system was foreseen. The system was constructed by the manufacturing

company that won the open tender (launched in March 2012) according to the technical

specifications that were produced during the design stage (Action 2) of the project

implementation. The engineering drawings of the system components are given in Annex I.

The report has been structured upon four (4) chapters, as follows:

Chapter 1, introduction of the report, provides general information regarding the

concept of the project as well as a brief description of the technical characteristics

of the prototype system;

Chapter 2 outlines the steps of the tendering procedure applied for the

construction, installation of the prototype system, as well as provides information

regarding the offers received, the winner of the competition and the detailed cost

breakdown of the system, including raw materials, construction and installation

costs.


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In Chapter 3 the construction of the prototype system is described, providing

photographic material. Additionally, an extensive list of suppliers/ manufacturers

that were contacted during the design and construction stage is given in Table 3-1;

Since after the construction of the different system components, the whole

prototype was assembled together. Information regarding the installation of the

system as well as a brief description of the site where the system was installed is

given in Chapter 4. It is noted that in this Chapter rich photographic material is

provided regarding the actual system that was installed at Agios Fokas desalination

plant;

Deliverable 3.1: Technical report on the installation and cost analysis of the constructed

pilot brine treatment system

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Περίληψη στα Ελληνικά

Στην παρούσα έκθεση παρουσιάζονται πληροφορίες σχετικά με την κατασκευή και

εγκατάσταση του πρότυπου συστήματος επεξεργασίας της άλμης το οποίο αναπτύχθηκε

στα πλαίσια του Ευρωπαϊκού προγράμματος SOL-BRINE (LIFE09 ENV/GR/000299).

Το εν λόγω σύστημα στοχεύει στην ολική εξάλειψη της άλμης που παράγεται από μονάδες

αφαλάτωσης. Οι ενεργειακές του απαιτήσεις θα καλύπτονται πλήρως από ανανεώσιμες

πηγές ενέργειας και συγκεκριμένα από ηλιακή ενέργεια. Η άλμη η οποία θα επεξεργάζεται,

παράγεται από υφιστάμενη μονάδα αφαλάτωσης, δυναμικότητας 1,000m3/ημέρα, η οποία

είναι εγκατεστημένη στην περιοχή του Αγίου Φωκά, στην Τήνο. Η ποσότητα που θα

λαμβάνεται προς επεξεργασία από την πιλοτική εφαρμογή θα αποτελεί ένα μικρό τμήμα

της συνολικής ποσότητας (



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Η παρούσα έκθεση διαρθρώνεται στα ακόλουθα τέσσερα (4) κεφάλαια:

Στο Κεφάλαιο 1 (Εισαγωγή), δίνονται γενικές πληροφορίες σχετικά με το έργο,

όπως επίσης και μία περιεκτική περιγραφή των τεχνικών χαρακτηριστικών του

συστήματος.

Στο Κεφάλαιο 2 δίνονται στοιχειά σχετικά με τον πρόχειρο μειοδοτικό διαγωνισμό

και πιο συγκεκριμένα πληροφορίες σχετικά με τις ληφθείσες προσφορές, τον

νικητή του διαγωνισμού και το κοστολόγιο του συστήματος.

Στο Κεφάλαιο 3, περιγράφεται η διαδικασία της κατασκευής του συστήματος. Η

περιγραφή του συστήματος συνοδεύεται από πλούσιο φωτογραφικό υλικό.

Σημειώνεται πως πριν την έναρξη του διαγωνισμού και κατά τη διάρκεια

υλοποίησης της Δράσης του σχεδιασμού (Δράση 2) και της Δράσης της κατασκευής

(Δράση 3), η ομάδα εργασίας ήρθε σε επαφή με μεγάλο πλήθος κατασκευαστών

και προμηθευτών (βλ. επίσης Table 3-1).

Κεφάλαιο 4: Μετά την ολοκλήρωση της κατασκευής των συνιστωσών του

συστήματος, το πιλοτικό συναρμολογήθηκε και εγκαταστάθηκε στην περιοχή του

Αγίου Φωκά, στην Τήνο. Οι εργασίες εγκατάστασης του συστήματος

ολοκληρώθηκαν στις 16 Οκτωβρίου 2012. Η περιγραφή της διαδικασίας

εγκατάστασης έχει εμπλουτιστεί με αντίστοιχο φωτογραφικό υλικό.

Κεφάλαιο 5: Το κεφάλαιο αυτό αποτελεί τα παραρτήματα της παρούσας έκθεσης.

Στο Παράρτημα Ι δίνονται τα μηχανολογικά σχέδια του συστήματος, ενώ στο

Παράρτημα ΙΙ δίνεται η σύμβαση που υπεγράφη μεταξύ του Αναδόχου

(ΘΕΡΜΟΣΩΛ ΑΕ) και της αναθετούσας αρχής (ΕΜΠ).



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1 Introduction

1.1 Background & Concept

The pilot brine treatment system was constructed in the context of the LIFE+ project SOL-

BRINE (contract No: LIFE 09 ENV/GR/000299) and was installed in the area of an existing

desalination plant (reverse osmosis unit with 1,000m3/day capacity) situated at the region

of Agios Fokas, Tinos Island, Greece.

The project aims at developing an energy autonomous brine treatment system for total

elimination of brine, while achieving high water recovery and production of marketable dry

salt. The system was designed to operate according to the Zero Liquid Discharge principle

(ZLD) (see Figure 1-1).

Within the framework of Action 3, the engineering, construction and installation of the

pilot-scale, energy-autonomous, brine treatment system is foreseen.

The system was constructed according to the engineering drawings (Annex I) that were

produced during the design stage (Action 2) of the project implementation. The reader can

find more information regarding the design of the prototype system at:

http://uest.ntua.gr/solbrine.

Figure 1-1: SOL-BRINE concept

http://uest.ntua.gr/solbrine/?lang=enhttp://uest.ntua.gr/solbrine



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1.2 Process description

In order to achieve Zero Liquid Discharge, all the amount of water must be gradually

removed from the brine effluent until solid salt crystals are obtained. In order for this to be

achieved the following units are employed (see also Figure 1-2):

Evaporator unit;

Crystallizer unit; and

Dryer.

Following, a brief description of the process involved within each of these units is discussed.

The reader can find more details at the relevant report on the results of the design stage

(Deliverable 2.4).

Intake: A small portion of the brine rejected from Tinos seawater desalination plant (~500

kg/day) is driven to the prototype system. The brine treatment system is fed with brine at

7% (measured at normal operating conditions) from the existing desalination plant situated

in Agios Fokas. The salt concentration of the brine introduced in the evaporator unit was

measured at 7%. This means that some 35kg of salt shall be produced by the pilot unit per

day of operation. The daily mass balance is given in Figure 1-2.

Evaporator unit

The evaporator unit is consisted of two (2) consecutive effects operated at decreasing levels

of pressure:

1st effect pressure: 0.30 atm(a);

2nd effect pressure: 0.15 atm(a).

In each of the evaporator effects, the brine is evaporated and two subsequent streams are

produced: (a) a water vapor stream, which is subsequently condensed and recovered as

fresh water, and (b) a more concentrated brine stream, which is driven to the subsequent

treatment stage. The vapor stream of the first effect is used for heating the concentrated

brine produced which is sprayed on the top of the bundle and runs down from tube to tube

by gravity. This way, the required latent heat for the vaporization of the brine in the second

file:///C:/Back%20up/My%20documents/Υλοποίηση%20προγραμμάτων/SOLBRINE/Deliverables/Action%203/Deliverable%203.1/uest.ntua.gr/solbrine/uploads/files/Deliverable2.4.pdf



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effect is provided by internal heat gain (heating steam from the first effect) and thus energy

recovery is achieved.

The vapor stream produced by the second effect is used for pre-heating purposes. More

pertinently, the vapor is passed through and condensed in a plate heat exchanger,

transferring its thermal energy to the inlet feed brine stream. Thus, thermal energy and

fresh water is recovered to the best possible extent.

The concentrated stream produced by the second effect is then passed to the crystallizer

unit where it is further concentrated. The concentration of the evaporator exit stream is

designed to be near saturation point (~26%).

Crystallizer

Both the crystallizer and the evaporator unit are based on the physical process of vacuum

evaporation. The crystallizer is consisted of a single vessel maintained at lower levels of

pressure (normal operating conditions: 5kPa 0.05 atm(a)). The crystallizer unit is

equipped with scraping blades inside the boiling vessel for allowing high evaporation rates

through cleaning of the heat transfer surfaces from the formed salt crystals and good

agitation. The vacuum is maintained through the combined use of a pump and an ejector.

Its purpose is to crystallize the brine effluent, producing a slurry (magma) with humidity

levels of approximately 50%. The whole process is characterized by energy efficiency

through the combined use of vacuum technology and heat pump.

Dryer

The magma leaves the crystallizer with an amount of moisture. In order to obtain the dry

salt products a solar dryer was employed.

Solar Energy System

The energy requirements of the pilot brine treatment system will be covered through the

use of solar energy. The thermal requirements will be supplied by concentrating evacuated

tube collectors through hot water at 80oC, while the electrical requirements through the use

of an autonomous photovoltaic generator (equipped with batteries for one day autonomy).

Deliverable 3.1: Technical report on the installation and cost analysis of the constructed pilot brine treatment system

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Figure 1-2: Single line diagram of the pilot brine treatment system


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500kg/day

(465kg H2O/day)

(35kg Salt/day)

330kg H2O/day

170kg/day

105kg H2O/day

30kg H2O/day

35kg Salt/day

65kg/day

Figure 1-3: Mass balance of the pilot brine treatment system. The quantities of distilled water produced are marked in pink, while the salt in blue color.



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2 Tendering

2.1 Type of tendering and process

An open tender was launched for the construction and installation of the brine treatment

system in March 2012. The process involved the following basic steps:

1. Submission of the request to the relevant authority of the NTUA (NTUA Research

Committee) for approval to carry out the tender;

2. Approval of the request by the NTUA-RC;

3. Preparation and submission of the Invitation To Tender (ITT);

4. Approval of the tender documents (ITT) by the Meeting of the NTUA-RC and

publication of the tender to the NTUA website and to national newspapers (see

Annex II);

5. Determination of the tender date and its subsequent publication on the NTUA

Research website (see also http://edeil.ntua.gr) as well as relevant newspapers

including at least the following information: the full set of specifications (see also

SOL-BRINE ITT), the deadline and preconditions for submitting an offer by NTUA-RC,

6. Execution of the tender on the prescheduled date by evaluating the tender offers;

7. Contract awarding to the winner of the competition.

2.2 Received offers and final selection

Three (3) offers were received from the following companies:

1. STEAMGAS, owned by Efthimios Kontos;

2. ΤHERMOSSOL SA, owned by Dimitrios Xenogiannis; and

3. SPECK HELLAS, owned by Gregoris Hatzigeorgopoulos.

The criterion for the final selection of the competition winner was the lowest bid, provided

that the bidder was found to be technically and financially acceptable. The evaluation of the

offers was realized in 04/04/2012 and THERMOSSOL SA was awarded as the winner of the

competition.

http://edeil.ntua.gr/anakoinwseis/diagwnismoi/diagwnismoi.html



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2.3 Detailed budget

The foreseen budget for the construction and installation of the pilot brine treatment

system was 90,530€. Due to limitations associated mostly with the aggressively corrosive

behavior of concentrated brine, the budget for constructing the pilot system was

substantially larger than originally planned (exceeded by approximately 20%). To this end, it

was decided to construct the system in two phases:

First construction phase (Phase I): full system excluding the photovoltaic generator.

All the necessary components for running the system were constructed, while its

electrical requirements will be provided by the public electricity network;

Second construction phase (Phase II): complete system (including the photovoltaic

generator). The electric requirements of the pilot unit will be met by the

photovoltaic generator that will be installed at later stages of the project

implementation.

It must be noticed that the tender was referring to the construction and installation of the

pilot system as described in Phase I. The cost breakdown of the system is given below:

Table 2-1: Cost breakdown of the pilot brine treatment system

Component Cost

Evaporator 43,000€

Crystallizer

(with heat pump for energy saving)

20,000€

Dryer 2,000€

Solar system 16,600€

Concentrating solar collectors 13,500€

Storage system (Phase Change Material, PCM) 3,100€

Control system 5,500€

Foundations 1,000€

Installation 1,000€

Housing of pilot system 1,000€

Total 90,100€



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2.4 Terms of the contract

The contract foresees the construction, transportation, installation and set-up operation of

the pilot brine treatment system. The system was installed at the region of Agios Fokas, on

Tinos Island.

The contract was signed on 28/06/2012 and the constructing period foreseen was eight

weeks (28/06/2012 – 23/08/2012). The signed contract is given in Annex II.



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3 Construction

The construction of the prototype system lasted approximately 3 ½ months, from June 28th,

2012 until October 16th, 2012. The actual construction schedule deviated from the original

plan due to complications with the acquisition of certain raw materials, namely austenitic-

ferritic stainless steel of special grade (Stainless Steel Super Duplex/ EN 1.4410/ UNS

S32750). The special grade was selected for avoiding pitting corrosion phenomena due to

the presence of high chloride concentration and increased temperature. The raw materials

were supplied by Sandvik Finland.

Selection of material:

Different materials were considered, including titanium, zirconium, copper nickel, aluminum

brass, stainless steel simple grade (316) and special grade (Super Duplex). The criteria that

were considered before the final selection of the material include but are not limited to the

following:

Corrosion Resistance. Resistance in the highly aggressive, corrosion environment due

to high temperatures and salt concentrations. The parameter examined was the

Critical Pitting Temperature (CPT) of the materials.

Raw materials availability. The system was constructed in Athens, Greece. No Super

Duplex industry exists on a local, regional or national level. Many companies that are

involved in the raw material supply industry, refused to import certain materials in the

required form and quantity. More particularly, many suppliers of Copper Nickel had

already stock material in the form of tube but not in the form of sheets. As a result a

combined use of Copper Nickel (tube) and Aluminium brass (sheet) had to be used.

This should be avoided due to galvanic corrosion limitations.

Cost-efficiency. In order for the developed system to be cost-efficient, the materials

used must be economical to the greatest possible extent. Even though sophisticated

materials such as titanium and zirconium exhibit very good corrosion resistance

behavior, they induced high cost burden to the acquisition and processing of the

materials. To this end, such materials were avoided.



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For the construction of the prototype a large number of suppliers/ manufacturers were

contacted. A list of the contacts is given in Table 3-1. Following photos from the

construction of the prototype are provided.

Figure 3-1: Raw materials (Super Duplex tubes and plates)



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Figure 3-2: Photos from the construction of the evaporator unit


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Table 3-1: List of suppliers/ manufacturers contacted

No. Company Name Contact Name Address Company Website Phone Number E-mail Address Notes

Evaporator, Crystallizer, Dryer

1. SUK Aggelakopoulos 14 Iasonos, Palaio Faliro, Athens,

Greece, 17564 http://suk.gr +30 210 971 9104 [email protected] Crystallizer

2. Alfa Laval Asteris Georgios 20th km, Lavrio Av., Karella, Koropi,

Athens, Greece, 19400 http://local.alfalaval.com/el-gr +30 210 668 3572 [email protected] Evaporator

3. Envitec Dimopoulos

Konstantinos

12 – 14 Agiou Ioannou Str., Halandri –

Athens, Greece, 15233 http://www.envitec.gr +30 210 685 5793 [email protected] Evaporator

4. Chemitec Lioumis Christos 23, Spyrou Vrettou str., Acharnes,

Greece, 136 71 GR http://www.chemitec.gr/ +30 210 244 7590 [email protected] Dryer

5. Maltezos Maltezos 66 Dragatsaniou Str, Pireaus, Greece,

185 45 http://www.pmaltezos.gr +30 210 461 2551 - Evaporator

6. Hellasenergy Mpouzianis

Konstantinos

10, Saint George Sq., Kipseli, Athens,

Greece, 112 57 http://www.hellasenergy.gr +30 210 822 2519 [email protected]

Evaporator, crystallizer,

dryer

7. Shielco Nakos Konstantinos 32A, 28 October Str., Pefki, Athens,

Greece, 151 21 http://en.shielco.com

+30 210 802 6515

[email protected] Evaporator, crystallizer

8. Thermossol

Steamboilers SA

Xenogiannis

Dimitrios

368A, Tatoiou Str., Acharnes,

Greece, 136.71 http://www.thermossol.gr +30 210 620 0630 [email protected] Evaporator, crystallizer

9. Liakos Tsiaras Christos 10, Dervenakion Str, Piraeus, Greece, 185

45 liakosrepairs.eu +30 210 463 0126 [email protected] Evaporator, crystallizer

10. Veoliawater Sales Manager Kings Place, 5th Floor, 90 York Way, N1

9AG, London http://www.veoliawater.com/ +33 1 49 24 49 24 - Evaporator, crystallizer

11. MageWater Seltman Torsten 8, Rudolf-Diesel Str.,

Odelzhausen, Germany, 85235 http://www.mage-watermanagement.com/ +49 813493 59987

seltmann@mage-

watermanagement.com Evaporator

12. Future Technology

Systems (FTS) SA Sittas Themis

1st Industrial Zone, Volos, Greece, 38

500 http://www.engineering.fts.gr/index.php

+30 24210 96 700

[email protected]


dryer

13. Entropie SAS Sandrine Bourdin 20-22 rue de Clichy, Paris, France,

75009 www.entropie.com +33 1 56 35 3529 [email protected] Evaporator

14.

Mage Water

Management

GMBH

Torsten Seltmann 8 Rudolf-Diesel-Strasse, Odelzhausen,

Germany, 85235 www.mage-watermanagement.com

+49 8134 935

9987

Seltmann@mage-

watermanagement.com Evaporator

http://suk.gr/index.php?option=com_content&view=article&id=83&Itemid=283&lang=elmailto:[email protected]://local.alfalaval.com/el-gr/Pages/default.aspxmailto:[email protected]:[email protected]:[email protected]://www.pmaltezos.gr/greek/company/default.htmhttp://www.hellasenergy.gr/index1.htmlmailto:[email protected]://en.shielco.com/0010000061/evaporators.htmlmailto:[email protected]:[email protected]:[email protected]://www.veoliawater.com/http://www.engineering.fts.gr/index.phpmailto:[email protected]:///C:/Back%20up/My%20documents/Υλοποίηση%20προγραμμάτων/SOLBRINE/Deliverables/Action%203/Deliverable%203.1/www.entropie.commailto:[email protected]://www.mage-watermanagement.com/mailto:[email protected]:[email protected]


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15. Wenzhou Taikang

Evaporator Co., Ltd. Allen Wang

No.700, the 7th Road, Binhai Industrial

Zone, Wenzhou, China http://www.wztaikang.com/en/ +86 577 86801989 [email protected]


dryer

16.

Suzhou Fenggang

Titanium Products

And Equipment

Manufacturing Co.,

Ltd.

Robby Yuan

368, Qianqiao Road, Fengqiao Town,

New District, Suzhou, Jiangsu Province,

China, 215129

www.szti.com +86 512 6653416

[email protected]


dryer

17. Michos SA Floros Nikos

1, Chrisostomou Smirnis, Neo Psychiko,

Athens, Greece, GR-15451

http://www.michos.gr/ +30 210 677 4280 [email protected] Compressor

18. Speck Hellas SA Hatzigeorgopoulos

Grigoris

54, Salaminos Str., Kallithea, Athens,

Greece, GR-17676 http://www.chatzigeorgopoulos.com

+30 210 958 8314

[email protected] Compressor

19. Fulton Systems Inc. Jeff Smith 5875 Peachtree Industrial

Suite 330, Norcross, GA 30092 http://www.fultonsystems.com +1 770 447 1400 [email protected] Compressor

20. Spraying Systems Hellas S.A.

Nicholas P. Pantazis 4, Tziraion str., Athens, Greece, 11742 www.spray.com +30 210 923 5051 [email protected] Evaporator

21. Thermoplasic Constructions

Spanidis Athanasios Boudoutsi 20 Str., Athens, Greece,

18538 - +30 210 463 4181 [email protected]

Raw Materials

22. Argyrakis Argyrakis - - +30 210 342 1202 - Copper, Aluminium

23. Emporohalko Vergopoulou 74, Irakleidon Str., Athens, Greece,

11854 http://www.emporohalco.gr/ +30 210 321 6250 [email protected] Copper, Aluminium

25. Metalchrom Kalavritinos

Nikolaos

32, Sostratou Str., Neos Kosmos,

Athens, Greece, 11854 http://www.metalchrom.gr/ +30 210 901 7584 [email protected] Metal plating

26. HALCOR

METAL WORKS S.A. Karakousi Katerina

Athens Tower - 2nd Building, 2-4

Mesogeion Ave., Athens, Greece, GR

115 27,

http://www.halcor.gr/ +30 210 686 1111 [email protected] Copper

27. Sandvik Leivadaros Antonis Kungsbron 1 (section G, floor 6) Str.,

Stockholm, Sweeden http://www.sandvik.com/ +30 210 682 3604 [email protected] Stainless Steel

28. Bobou Bobou Dimitra 12, Mavromihali Kiriakou Str., Piraeus,

Greece, 18545 - +30 210 411 4935 - Copper, Alumium Brass

http://www.wztaikang.com/en/mailto:[email protected]://www.szti.com/Tel:86-512-66653416mailto:[email protected]:[email protected]://www.spray.com/http://www.emporohalco.gr/mailto:[email protected]://www.metalchrom.gr/mailto:[email protected]://www.halcor.gr/javascript:void(location.href='mailto:'+String.fromCharCode(105,110,102,111,64,104,97,108,99,111,114,46,118,105,111,110,101,116,46,103,114)+'?')http://www.sandvik.com/mailto:[email protected]


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29. Rentas Ioannis SA Renta Tatiana 9, Mavromihali Kiriakou Str., Piraeus,

Greece, 18545 http://www.rentas.gr/ +30 210 417 6682 - Copper, Alumium Brass

30. Spanidis Spanidis Athanasios - - +30 210 463 4181 - Plastic

31. Tarinas Eustratios Tarinas Stratis 40, Retsina Str., Piraeus, Greece, 18545 - +30 210 412 3511 [email protected] Copper, Alumium Brass

32. Texnisis Tsaousis Nikolaos 28, Agion Asomaton Str., Athens,

Greece, 105 53 - +30 210 321 4531 [email protected] Metals

33. Technometal SA Oikonomou 20, Dragatsaniou Str., Peiraeus, Greece,

18545 http://www.txmetal.gr +30 210 422 6251 [email protected] Stainless Steel

34. National Metal Distributors

Kathy Jameson 12323 NE 99th Street, Vancouver,

United States of America, WA 98682 http://www.nationalmetaldistributors.com/ +1 800 878 3675 [email protected] Stainless Steel

35. Pyrogenesis SA Vardavoulias

Mihalis Technical Park of Lavrio, Lavrio, Greece,

19500 http://www.pyrogenesis-

sa.gr/Template%202/nanospray_Gr.html +30 22920 23477 [email protected] Metal Plating

36. Chryssafidis Antonis Kovas

3, Agriniou Str. Tavros, Athens, Greece

177 78 http://www.chryssafidis.gr +30 210 483 6315 [email protected]

Stainless Steel (Sole agent of

Spirax Sarco in Greece)

Control

37. Energineering Vasilopoulos

Anastasios - - +30 211 790 0051 [email protected]

Control for solar thermal

system – Design of PCM

storage system

38. Automation

Technique SA Ovvadias Dimitris 46 Chiou Str, Athens, Greece, 104 39 http://www.automationtechnique.gr/en/

+30 210 882 3464

[email protected]

Industrial Automation

Systems

Solar Thermal System

39. Calpak SA Kourmpoglou

Miltos 9, Sygrou Av., Athens, Greece, 11743 http://www.calpak.gr/ +30 210 963 8840 [email protected] Evacuated Tube Collectors

40. Antares Konstas Kostas 235, Marathonos Av., Pikermi, Athens,

Greece http://www.antares.com.gr/ +30 210 604 3507 [email protected] Evacuated Tube Collectors

41. Sanet Maglaras Dimos 209 Tatoiou Av., Ind. Park

Metamorphosis, Athens, Greece, 14452 http://www.sanet.gr/mag.php +30 210 572 6605 [email protected]

Concentrated, Evacuated

Tube Collectors

42.

43. Spirax Sarco Keith Woolnough 1150 Northpoint Blvd., Blythewood, SC

USA, 29016 http://www.spiraxsarco.com/ +1 (800) 575-0394 [email protected]

Steam Accumulator for PTC

system

http://www.rentas.gr/mailto:[email protected]:[email protected]://www.txmetal.gr/index.phpmailto:[email protected]:[email protected]://www.chryssafidis.gr/profile.phpmailto:[email protected]:[email protected]://www.automationtechnique.gr/en/mailto:[email protected]://www.calpak.gr/mailto:[email protected]://www.antares.com.gr/mailto:[email protected]://www.sanet.gr/mag.phpmailto:[email protected]://www.spiraxsarco.com/mailto:[email protected]


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44.

Silcio Solar

Technologies

Drakopoulos

38-40 Kapodistriou Av, Maroussi

Athens, Greece, GR-15123

http://www.silcio.gr/ +30 210 684 8506

[email protected]

Photovoltaic generator

45. Heliosphera SA Sergiannidis

37A Kifissias Av., GOLDEN HALL,

Building A, 2nd Floor, Maroussi, Athens,

Greece, 15123,

http://www.heliosphera.com/ +30 210 641 2009 [email protected] Photovoltaic generator (thin

film)

46. Cocoon Solar Energy

Mihalis Koutsouris 8, Miaouli Str., Athens, Greece, 10554 www.cocoon.gr +30 210 325 0458 [email protected] Photovoltaic generator

47. Solar Cells Hellas Sehremeli Giota

64, Kifissias Av. & Premetis, Athens,

Greece, 15125

http://www.schellas.gr/en +30 210 959 5159

- Photovoltaic generator

48. Acciona (Website Contact

Form) (Website Contact Form)

http://www.acciona-

energia.com/activity_areas/csp.aspx

(Website Contact

Form) (Website Contact Form)

Parabolic Trough Collectors

(PTC)

49. Abengoa Cen May 1909 K Str., NW, Suite 840,

Washington, DC 20006 http://www.abengoasolar.com/ +1 (303) 323 9505 [email protected]


(PTC)

50. NEP SOLAR AG Florian Pithan Technoparkstrasse 1, Zürich,

Switzerland, 8005 http://www.nep-solar.com/ +41 44 445 1695 [email protected]


(PTC)

51. ACS-Cobra - 10, Cardenal Marcelo Spinola, Madrid,

Spain, 28016 http://www.grupocobra.com +34 914569500 [email protected]


(PTC)

52. Flabeg Holding

GmbH -

13, Waldaustraße Str., Nürnberg,

Germany, 90441 http://www.flabeg.com +49 911 964560 [email protected]


(PTC)

53. Flagsol GmbH -

30 Agrippinawerft Str., Köln (Cologne)

Germany, 50678 http://www.flagsol-gmbh.com/flagsol/cms/

+49 221 925 970 -

0 [email protected]


(PTC)

54. Fichtner Solar

GmbH -

3, Sarweystraße, Stuttgart, Germany,

70191 http://www.fichtnersolar.com/

+49 711 899

51870 [email protected]


(PTC)

55. Kingspan

Environmental Ltd. Katherine Raghfar

180 Gilford Road

Portadown, Co. Armagh

United Kingdom, BT63 5LF

www.kingspan-renewables.com +44 (0)787901

2504 [email protected] Thermal Solar Collectors

56. Schott AG - 10, Hattenbergstrasse Str., Mainz

Germany, 55122 http://www.schottsolar.com/us/home/ +49 (0)6131/66-0 - Glass for PTC

http://www.silcio.gr/mailto:[email protected]://www.heliosphera.com/mailto:[email protected]://www.cocoon.gr/mailto:[email protected]://www.schellas.gr/enhttp://www.abengoasolar.com/mailto:[email protected]://www.nep-solar.com/mailto:[email protected]://www.grupocobra.com/indexframe_in.htmlmailto:[email protected]:[email protected]:[email protected]:lp%40fichtner.dehttp://www.kingspan-renewables.com/mailto:[email protected]


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57. Solitem GmbH -

24, Uersfeld, Aachen, Germany, 52072 http://www.solitem.com.tr

+49 (0)241980

9060 [email protected]


(PTC)

http://www.solitem.com.tr/en/node/70tel:%2B49%20%280%29241%20980%20906-0tel:%2B49%20%280%29241%20980%20906-0mailto:[email protected]



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4 Installation

4.1 Basic description of the site

The pilot brine treatment plant was installed at the site of an existing desalination unit at

the region of Agios Fokas, on Tinos Island. Before the final selection of the area where the

pilot system was installed, all alternatives within the site of the desalination plant (see

Figure 4-1) were examined with due care in order to decide on the best available location

for the installation of the system in terms of installation simplicity (e.g. accessibility by road

for equipment transportation), utilities accessibility (electricity, water supply), proximity to

brine discharge point etc. The final decision was made during the second management

meeting in collaboration with the project Steering Committee (for more information see

Deliverable 8.2).

Northern view of the site

Southern view of the site

North-western view Western view of the site

Eastern view

Discharge point

Figure 4-1: Views of the site of the desalination plant at Agios Fokas, Tinos Island



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The selected location comprises a flat area, 250m from the coastline with connection to the

road and the utilities networks of the island. A map of the area is provided in Figure 4-2.

Note: the area marked in yellow represents the area where the pilot system has been installed, while the area bordered with the dashed line represents the site of the desalination plant.

Figure 4-2: Site of the pilot brine treatment plant

250 m

(Distance of the plant from the shoreline)



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4.2 Civil work

The civil work included the following:

Site preparation works, for cleaning (e.g. from vegetation) and flattening of the area

(see Figure 4-3);

Laying down a 110 square meter foundation platform (see Figure 4-4 and Figure

4-5).

Figure 4-3: Site preparation works of the area where the pilot system was installed



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Figure 4-4: Civil works for laying down the foundations of the system

Figure 4-5: Foundations of the brine treatment system



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4.3 Installation of the equipment

All system components were installed on the 110m2 concrete platform as shown in Figure

4-6. The installation involved low permitting complexity as the pilot system comprises in

essence a zero liquid discharge system: only a license from the Planning and Architecture

Control Committee was required.

The installation of the system lasted nine (9) days, as follows:

2 days (from 26/09 to 27/09) for the solar system (see Figure 4-7);

2 days (from 12/10 to 13/10) for the dryer (see Figure 4-8) and;

5 days (from 12/10 to 16/10) for the crystallizer and evaporator units (see Figure

4-10 and Figure 4-11).

Legend

Evaporator

Crystallizer

Dryer

Solar system (concentrating evacuated tube collectors, Greek patent) d

c

b

a

d

a

b

c


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Figure 4-6: Layout of pilot brine treatment system



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Installation of the solar system (26-27/09/2012)

Fully installed system

Figure 4-7: Solar system



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Installation of the dryer – 12-13/10/2012

Dryer fully installed (details)

Figure 4-8: Installation of the dryer

2 m (Width)

6 m (Length)

1 m (Height)



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Figure 4-9: Transportation of the evaporator unit from the manufacturer’s workshop facilities

Transportation of the evaporator unit

with overhead bridge crane (workshop

facilities of Thermossol Company)

Placement of the evaporator unit on the

crane transportation vehicle (prior its

shipping to Tinos Island) – 12/10/2012

http://www.thermossol.gr/



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Figure 4-10: Details from the fully installed evaporator unit



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Transportation (JCB vehicle,

photos on the top) and

placement (chain pulley

block, photo on the left) of

the crystallizer unit –

16/10/2012

Figure 4-11: Crystallizer unit



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4.4 Control

Table 4-1 shows a list of sensors and components applied for instrumentation and in

particular it contains: (a) pumps (P-xxx), (b) control valves (CV-xxx), (c) flow meters (F-xxx),

(d) pressure transmitters (P-xxx), (e) temperature transmitter (T-xxx), (f) level transmitter

(LT-xxx).


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Table 4-1: Instruments for the control and monitoring of the prototype brine treatment system

No TAG Description Input From Exits To

Signals from/to PLC

Digital Analog

Input Output Input Output

1. P-002 Vacuum pump CV-009 - 2 1 0 0

2. P-003 Distillate reciprocating pump, 100 lt/h @ 1.5 bar K-001 Water Collection Tank 2 1 0 0

3. P-004 Brine pump K-002 Crystallizer 2 1 0 0

4. CV-001 Control Valve T-002 F-001 1 0 1 1

5. CV-007 Control Valve K-001 P-003 2 1 0 0



8. CV-017 Control Valve W-007 K-001 1 0 0 1

9. F-001 Flowmeter, 4-20mA CV-001 T-003 0 0 1 0

11. FSC-001 Flowmeter, 4-20mA Collectors TSC-002 0 0 1 0

12. P-022 Pressure transmitter Feed brine pressure 0 0 1 0

13. P-018 Pressure transmitter W-004 K-001 0 0 1 0

14. P-006 Pressure Transmitter W-001 W-002 0 0 1 0

15. T-022 Temperature Transmitter, PT1000 Feed brine temperature 0 0 1 0

16. T-002 Temperature Transmitter, PT1000 W-004 CV-001

17. T-003 Temperature Transmitter, PT1000 W-006 W-009 0 0 1 0





22. T-017 Temperature Transmitter, PT1000 W-007 CV-017 0 0 1 0


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No TAG Description Input From Exits To

Signals from/to PLC

Digital Analog

Input Output Input Output

23. TSC-001 Temperature Transmitter, PT1000 Solar system 0 0 1 0

24. TSC-001 Temperature Transmitter, PT1000 Solar system 0 0 1 0

25. LC-003 Level Transmitter W-001 1 0 0 0

26. LC-005 Level Transmitter W-002 1 0 0 0

27. LC-006 Level Transmitter

K-001

1 0 0 0

28. LC-007 Level Transmitter 1 0 0 0


30. LC-009 Level Transmitter

K-002

1 0 0 0



35. Other Other components - - - - -


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5 Annexes

Annex I: Engineering Drawings

Figure 5-1: Engineering drawings of the evaporator vessel (Effects 1&2)


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Figure 5-2: Process and Instrumentation Diagram (P&ID)


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Figure 5-3: Products discharge vessels (two identical vessels: one for the fresh water produced and one for the treated brine (crystallizer))


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Figure 5-4: Tube in Tube Heat Exchanger


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Note: The drawing of the evaporator unit is being modified as appropriate in order to integrate all final construction modifications

Figure 5-5: 3-D Views of the evaporator unit


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Figure 5-6: Drawing of the dryer



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Annex II: Signed Contract

Sol – Brine

LIFE+ Environment project: LIFE09 ENV/GR/000299

Documents

Sol - Brinesolbrine.uest.gr/uploads/files/deliverable_3.1.pdf · pilot brine treatment system 5 | P a g e 1 Introduction 1.1 Background & Concept The pilot brine treatment system